FREYSSIBAR

The prestressing bar for civil works

D e s i g n ,

B u i l d ,

M a i n t a i n

C III 3

FREYSSIBAR
Prestressing system
Developed by Freyssinet, worldwide leader in prestressing activities,
the Freyssibar prestressing system comprises a wide range of threaded
bars and associated anchoring, coupling and extension devices.
This prestressing system is adapted to many applications.
Among these are :
Permanent or temporary prestressing
Holding down bolts for cranes, wind turbines, etc.
Bridge construction systems
Ground and rock anchors, rock bolts
for geotechnical, mining, tunnelling works
Heavy lifting
Tie rods for marine works

Freyssinet is the holder of the European Technical Approval

(ETA) n ETA 09/0169 for the Freyssibar post-tensioning kit for
prestressing of structures.
The Freyssibar flat anchorages and couplers for fully threaded
bars up to 50 mm are approved to the requirements of ETAG 013.
Freyssinet has also obtained the EC-certificate of conformity:
certificate n1244-CPD-1014. The ETA and the EC-marking are
followed by a notified body.

Contents
Technology

p3

Installation

p6

Characteristics

p8

Ground and
rock anchors

p 11

Technology
The bars
The bars are hot rolled from high strength alloyed steel. They are subsequently cold worked by stretching and then threaded over their full length or
on the extremities by cold rolling. The standard range of nominal diameters
is: 26.5; 32; 36; 40 and 50 mm. Non-standard diameter bars can be delivered
on request.
The fabrication process provides a high quality thread
ensuring high fatigue resistance and a low susceptibility to stress corrosion.
The nature of the Freyssibar manufacturing method
also ensures that every single bar is stress tested to
85% of the guaranteed ultimate tensile strength of the
bar.
The geometry of the thread is specifically designed to
ensure ease of use on site, providing fast, accurate and
easy tightening.
Bars are available in maximum lengths of 11.8 meters.
Beyond this length, extension sleeves allow bars to be
Lifting : prestressed connection between
a segment and a beam.

connected together.

The anchorages
The anchor devices are designed to anchor the force in the bar and transfer it to
the structure. Four types of anchorages are available:
Standard anchorages with a nut and washer;
Hinge anchorages using a nut with a spherical seat;
Standard anchorages using a low rotation spherical nut and spherical washer;
Fixed anchorages using a threaded end plate.
All nuts are hot forged. Also, couplers allow primary bars to be connected to
secondary bars.

The accessories
Freyssinet offers a full range of sheathing that is easy to install.
In particular:
Steel strip corrugated sheath, threaded over its full length, which allows easy
and fast connections;
High density polyethylene tube, with elements mirror welded to achieve
a leak free and non corrodible envelope;
Sheathing accessories specific to the tensioning and coupling devices, required
to fit the coupler geometry. The length of the ducting element used is project
specific, so as to allow the coupler displacement over a sufficient length during
Anchorage of steel ropes

the tensioning operations.

Technology

Properties
Fatigue : The system has a fatigue resistance in excess of two million cycles of
loading over a tensile stress range of 590-670 N/mm2, exceeding the ETAG 013
requirements.
Relaxation : After 1000 hours the loss of stress due to relaxation in the Freyssibar
system loaded to 70% Fpk is below 3% which is better than the 4% maximum as
described in pr EN 10138-4.
Anchorage strength : Freyssibar post-tensioning system is tested to ensure that
the failure load on the bar with coupler and anchorage is more than 95% of the
strength of the bar alone.

Protection against corrosion

Stress corrosion tests have been performed in accordance to prEN 10138. The
bars have been stressed under corrosive environment during 500 hours and
passed the subsequent tensile test to failure. Freyssibar is not susceptible to
stress corrosion but depending on the conditions of exposure, a specific corrosion
protection can be applied under request.
The corrosion protection system is selected in accordance to the expected
design life time and the conditions of exposure.

Permanent ties for quay walls

Surface coating
Hot dip galvanizing after sand blasting (no risk of hydrogen embrittlement due
to acid pickling)
Metalization (Dunois, etc.)
Petrolatum tape
Epoxy coating

Specific injection products

Wax : hot injection
Grease

Allow for subsequent re-tensioning of the bars

Cement grout : alkaline environment

Ducting
Corrugated ducts: light and easy to install
Smooth pipes: stiff and resistant to shock
Ducts and pipes can be either in steel or in HDPE (non corrodible).
Different protection systems can be combined to enhance the degree of protection.

Quality control
The fabrication of the bars and the anchorages is carried out under a quality
assurance system in compliance with the quality standard ISO 9000 : 2000. Flat
anchorages and bars have passed all the tests required in ETAG 013.
Prefabricated bar tendons

Ground anchors

Installation

The accuracy of the prestressing force actually introduced into the structure
and the durability of the tendons depend on the quality of the installation. The
detailed installation procedure is available on request.

Shimming of the anchorages

When anchorages are applied onto an existing concrete element, it is recommended to shim under the bearing plate using a non-shrink mortar, free from
chlorides.

Tensioning
The tensioning equipment provided by Freyssinet ensures the accuracy of the
load applied within +/- 2%. This is achieved through regular calibration of the
pump pressure gauge and the jacks.

Safety factors
The maximum allowable stressing force in the prestressing bars is given by the
relevant design standards. Recommendations are given below as examples:
(Note: Fpk means the guaranteed tendon tensile breaking load and Fp0.1%
means the proof load).
Load cell

A/ In post-tensioned structures, the Eurocode limits the tension

to either 0.9 Fp0.1% or 0.8 Fpk, whichever is lower.
B/ In prestressed ground anchors, the norm EN 1537 prescribes a final
force limited to 0.75 Fp0.1% for temporary ground anchors and
0.60 Fp0.1% for permanent ground anchors.
C/ In case of re-use, the tensioning force of the bar is limited to 0.60 Fpk
for the first use, and to 0.50 Fpk for all subsequent uses.

Stressing with the hinged jack

Injection

Precast segments assembly

Two types of jacks

Two types of jacks can be used: with a tie rod connected to the tendon or with
a direct connection. Jacks should be used in conjunction with Freyssinet hydraulic
pumps, with high pressure and a low flow rate to allow a progressive tensioning
of the bar. Space must be allocated around the anchorage to allow the correct
installation of the jack.

Service
Freyssinet, world leader in prestressing, offers:
worldwide advice for specific works, from our specialists,
a huge material park providing jacks and equipment for the best
application of the Freyssibar installation,
an on site technical assistance given by our highly qualified
technicians, at the time of installation.

Injection accessories

Characteristics
Bar
Characteristic

Unit

Steel grade

Nominal diameter (mm)

26.5

32

36

40

50

MPa

1030

1030

1030

1030

1030

Cross section area

mm

552

804

1018

1257

1964

Linear mass

kg/m

4.56

6.66

8.45

10.41

16.02

Characteristic breaking load : Fpk

kN

568

828

1048

1295

2022

0.1% proof load

kN

461

672

850

1049

1640

Tensionning force at 0.80 x Fpk

kN

454

662

838

1036

1618

Thread pitch

mm

Average Youngs modulus

GPa

170

170

170

170

170

Minimum elongation at maximum force

3.5

3.5

3.5

3.5

3.5

Ref.

You can order all the products presented in the above table on www.freyssibar.com

Flat anchorage
Nominal bar diameter (mm)
Item

Sketch

Flat nut
Flat washer

Flat plate

Injection plate

Dimensions

Unit

Length

26.5

32

36

40

50

mm

37

41

46

55

71

Width on flat surface

mm

50

56

62

65

90

External diameter

mm

65

70

75

80

105

Thickness

mm

Dimensions

mm

Thickness

mm

Hole diameter

mm

Dimensions

mm

Thickness

mm

35

35

40

40

45

Hole diameter

mm

34

40

44

50

60

Ref.

N
W

110x125 125x125 140x160 160x160 200x200

35

35

40

40

45

34

40

44

50

60

FP

110x125 125x125 140x160 160x160 200x200

FPG

You can order all the products presented in the above table on www.freyssibar.com

Fixed anchorage
Item

Threaded plate
Welded cap
(option)
Available upon request

Sketch

Nominal bar diameter (mm)

Dimensions

Unit

Dimensions

mm

Thickness

mm

40

50

50

60

70

Length

mm

15

20

20

25

25

26.5

32

36

40

50

110x125 125x125 140x140 150x150 185x185

Ref.

TEP
CW

You can order all the products presented in the above table on www.freyssibar.com

Spherical anchorage type 1 3

Item

Sketch

Spherical nut

Spherical plate

Dimensions

Unit

Length

Nominal bar diameter (mm)

26.5

32

36

40

50

mm

45

51

56

60

71

Width on flat surface

mm

50

56

62

65

90

Dimensions

mm

Thickness

mm

160x115 160x125 160x140 160x160 190x190

40

40

40

40

60

Ref.

SN

SP

You can order all the products presented in the above table on www.freyssibar.com

Spherical anchorage type 2 0.6

Item
Spherical nut
Type 2
Spherical
washer

Flat plate

Injection plate

Sketch

Dimensions

Unit

Nominal bar diameter (mm)

26.5

32

36

40

50

Length

mm

37

41

46

55

71

Width on flat surface

mm

50

56

62

65

90

External diameter

mm

75

80

90

95

125

Thickness

mm

10

10

10

10

15

Dimensions

mm

Thickness

mm

35

35

40

40

45

Hole diameter

mm

34

40

44

50

60

Dimensions

mm

Thickness

mm

35

35

40

40

45

Hole diameter

mm

34

40

44

50

60

Ref.
SN
Type 2
SW
Type 2

110x125 125x125 140x160 160x160 200x200

FP

110x125 125x125 140x160 160x160 200x200

FPG

You can order all the products presented in the above table on www.freyssibar.com

Couplers
Nominal bar diameter (mm)
Sketch

Dimensions

Unit

External diameter
Length

26.5

32

36

40

50

mm

45

50

60

65

76

mm

90

115

130

140

170

Ref.

You can order all the products presented in the above table on www.freyssibar.com

Accessories
Nominal bar diameter (mm)
Item

Formwork tube

Caps

Dimensions

Unit

Length

26.5

32

36

40

50

mm

250

250

250

250

250

External diameter

mm

42.9

48.5

50.8

57.2

70

Thickness

mm

Ref.

Air vent connection

1/2

1/2

1/2

1/2

1/2

Short caps

Length

mm

95

100

120

120

150

CS

Long caps

Length

mm

210

220

220

220

280

CL

You can order all the products presented in the above table on www.freyssibar.com

Ducts
Nominal bar diameter (mm)
Item

Steel corrugated sheath

HDPE tube

For prolongation sleeve

For coupling sleeve

Dimensions

Unit

Internal diameter

26.5

32

36

40

50

mm

45

50

55

60

75

Thickness

mm

0.45

0.45

0.45

0.45

0.50

Volume of grout

L/m

0.10

0.12

0.14

0.16

0.25

Connection element (internal diameter)

mm

50

55

65

70

85

Internal diameter

mm

63

63

75

75

90

Thickness

mm

5.8

5.8

6.8

6.8

8.2

Volume of grout

L/m

0.15

0.13

0.19

0.17

0.23

External diameter

mm

70

76.2

88.9

95

114.3

Thickness

mm

Minimum length (L = sleeve)

mm

180 + L

205 + L

220 + L

230 + L

260 + L

External diameter

mm

88.9

88.9

101.6

114.3

152.4

Thickness

mm

Maximum length

mm

210

235

255

265

320

Ref.

G1
G1
G2

GR

GC

You can order all the products presented in the above table on www.freyssibar.com

10

Ground and
rock anchors
The Freyssibar prestressing bars, thanks to their thread over their full length,
allow to build ground and rock anchors fulfilling the requirements of international
standards. Lengths over 12 m can be obtained by means of one or several sleeves.
The ducting accessories and the anchorage corrosion protection systems are
adjusted to the design life time of the anchor: temporary or permanent.
In addition, the anchors can be fitted with injection tubes to fill the bore hole and
reinjection tubes to improve the bonding to the substrate.

PERMANENT

Nominal diameter bars (mm)

Spherical anchorage

Item

Dim.

Steel formwork tube

Ref.

26.5

32

36

40

50

80

89

89

89

108

FTUB

Plastic smooth sheath

60

70

70

75

90

STUB

Plastic ribbed sheath

55

65

65

70

85

RTUB

Plastic spacer

95

105

105

110

125

SPC

End protective cap

95

101,6

114,3

114,3

139,7

CE

Anchor plate

You can order all the products

presented in the above table on
www.freyssibar.com

Ribbed sheath
Spacer
Protective cap

Cap

Flexible anticorrosion product

Smooth sheath

Nominal diameter bars (mm)

Item

Dim.

Plastic smooth sheath

Plastic spacer

32

36

40

50

50

50

50

60

65

SPC

55

60

65

80

90

CE

TEMPORARY

Spherical anchorage

Spacer

Cap

Smooth sheath

11

Ref.

26.5

You can order all the products

presented in the above table on
www.freyssibar.com

More than 60 offices worldwide

EUROPE
Belgium
Freyssinet Belgium N.V.
Bulgaria
Freyssinet

Danemark
A/S Skandinavisk
Spaendbeton
Estonia
Latvijas Tilti
France
Freyssinet France
Freyssinet International & Cie
Hungary
Pannon Freyssinet Kft
Iceland
A/S Skandinavisk
Spaendbeton
Ireland
Freyssinet Ireland
Latvia
Latvijas Tilti
Lithuania
Latvijas Tilti
Macedonia
Freyssinet Balkans
Netherlands
Freyssinet Nederland B.V.
Norway
A/S Skandinavisk Spaendbeton
Poland
Freyssinet Polska Sp. z.o.o

Portugal
Freyssinet - Terra Armada S.A
Romania
Freyrom
Russia
Freyssinet
Serbia
Freyssinet
Slovenia
Freyssinet Adria SI d.o.o.
Spain
Freyssinet S.A.
Sweden
A/S Skandinavisk Spaendbeton
Switzerland
Freyssinet S.A.
Turkey
Freysas
United Kingdom
Freyssinet Ltd

AFRICA AND MIDDLE EAST

Abu Dhabi
Freyssinet Middle East LLC
Algeria
Freyssinet Algrie
Dubai
Freyssinet Gulf LLC
Egypt
Freyssinet Menard Egypt SAE
Jordan
Freyssinet Jordan LLC
Koweit
Freyssinet Koweit
Morocco
Freyssima
Oman
Freyssinet Arabian Sea LLC
Qatar
Freyssinet Menard Qatar WLL

Saudi Arabia
Freyssinet Menard Saudi Arabia Ltd.
Sharja
Freyssinet Menard
Northern Emirates LLC
South Africa
Freyssinet Posten (Pty) Ltd
Tunisia
Freyssinet
ASIA
Hong Kong
Freyssinet Hong Kong Ltd
Freyssinet Insight Sewer Services Ltd
India
Freyssinet Menard INDIA Pvt Ltd
Indonesia
PT Freyssinet Total Technology
Japan
Freyssinet KK Japon
Macau
Freyssinet Macau Ltd
Malaysia
Freyssinet PSC (M) SDN BHD
Pakistan
Freypak Ltd

1 bis, rue du Petit Clamart 78140 Vlizy-Villacoublay - France

Tel: +33 1 46 01 84 84 - Fax: +33 1 46 01 85 85
www.freyssinet.com - www.freyssibar.com

Singapore
PSC Freyssinet (S) Pte. Ltd
South Korea
Freyssinet Korea Co. Ltd
Taiwan
Freyssinet Taiwan Engineering
Thailand
Freyssinet Thailand Ltd
Vietnam
Freyssinet Vietnam
OCEANIA
Australia
Freyssinet Australia Pty Ltd
New Zealand
Freyssinet New Zealand Ltd

March 2010

AMERICAS
Argentina
Freyssinet - Tierra Armada S.A.
Brazil
Freyssinet Brazil Ltda
Canada
Freyssinet Canada Lte
Chile
Freyssinet Tierra Armada Chile S.A
Colombia
Freyssinet Colombie
El Salvador
Fessic S.A De C.V.
Mexico
Freyssinet de Mexico - Tierra Armada S.A.
Panama
Freyssinet
United States
Freyssinet Inc.
Venezuela
Freyssinet - Tierra Armada CA